1

2. Operation of boiler feed pumps, condensate pumps, and feed water heaters

1. Boiler feed pumps
A boiler feed pump ensures continuous supply of feed water to the boiler, preventing
overheating and damage to the boiler. The boiler feed pump is an essential part of the boiler feed
system. The article explains the construction and working of a boiler feed pump.

1.1 Introduction
A feed pump supplies feed water to the boiler as and when required. An essential part of
the Boiler feed water system, a boiler feed pump is selected according to the quantity and the
amount of pressure required by the boiler. The feed pump raises the pressure of the feed water
to a level high enough for the water to enter the boiler. The type of the boiler also plays an
important role in selecting a feed water pump. For example, in case of auxiliary boilers, where
the amount of feed water required is less, a steam driven reciprocating positive displacement
pump is generally used.

1.2 Reciprocating Boiler Feed Pump
The positive displacement reciprocating pumps are double acting pumps; which means that
the liquid enters the boiler feed pump on either sides of the pump piston. Thus, when the piston
moves up, suction is taken in the area below the piston and the liquid is drawn in. During the
intake of the liquid, only the suction valve is open and the design is made in such a way that
discharge valve remains shut. As the piston moves up, discharge valve on the top side of the
piston opens, pushing the water out, while the suction valve remains closed. As the piston
moves in the downward direction, the same operation is repeated in the upper part of the
piston. In this way, the suction and discharge occurs on the opposite sides of the piston of the
boiler feed pump.
All the positive displacement reciprocating pumps are self priming pumps, which produce
the pressure required by the system. The pump is not affected by the intrusion of vapors or
gases inside the pump system. Yet the pump is always provided with an air vessel at the
discharge pipe to reduce the effects created by the pressure variations at the time of discharge.
Due to high occurrences of pressure fluctuation inside the pump, the pump system is fitted with
a relief valve in between the suction and discharge chambers in order to protect the pump.

2

1.3 Turbo-Feed Boiler Pump
The systems having steam turbine driven feed pumps usually have a high pressure water
tube installations. The turbo-feed pump is a two stage horizontal centrifugal pump, which is
driven by an impulse turbine. The whole arrangement includes a diffuser and a volute casing
along with the impulse turbine. The pump runs with the help of direct steam from the high
pressure boiler. The exhaust steam from the turbine is send to the pre-heater for feed heating.
The bearings of the pump are lubricated with the help of filtered water supplied from an inlet
opening provided in the first stage of the pump.
In most of the systems, the feed water supply is controlled with the help of a feed water
controlled system, also known as the cascade system. The pressure of the feed discharged is
controlled with the help of a governor. For the safety of the system, over-speed protection trips
are also provided.
Another type of feed pump known as "electro feeder" is generally used in packaged boiler
installations. An electro feeder type of a pump is a multistage centrifugal pump, driven by a
constant speed electric motor. The number of stages required by the boiler feed pump depends
on the feed quantity and discharge pressure.



2. Condensate pumps
Centrifugal pumps are almost exclusively given the job of condensate pumping. For one thing,
the self-regulating character of submergence control simplifies many condensate pumping
installation, particularly those from vacuum regions.
The single-acting, double suction pump has the widest range of application and can serve for all
condensate drainage except those cases with high discharge pressure. Then 2-stage axially balanced
pumps are needed.
Another application of the centrifugal condensate pump is the integrated condensation
pumping set. These sets are employed to receive assorted flows of condensate from traps, heating
3

systems, etc., and deliver the condensate to the feedwater tank. On a common base will be
mounted a motor-driven centrifugal pump, a receiver tank of steel or cast iron, and the necessary
valves, strainers, controls. Usually the control is a simple, float-operated switch that starts the motor
when the tank has been nearly pumped out. By venting the tank, hot trap discharges are cooled to
212 F through flashing; hence the pump must be designed to operate on a few inches suction
submergence, although pumping hot water.

3. Feedwater heaters
Feedwater heaters have two primary functions in power plants: (1) to provide the means for
increasing the feedwater temperature, which improves the overall plant efficiency, and (2) to
minimize the thermal effects in the boiler. Feedwater heaters use steam from selected turbine
extraction points to preheat the feedwater from the condenser prior to it entering the economizer
or boiler drum.
The number and type of feedwater heaters used depend on the steam cycle, the operating
pressure of the cycle, and the plant economics, i.e., where lower operating costs can offset the
additional capital cost expenditure. In general, smaller plants have fewer units. In utility and large
industrial plants, five to seven stages of feedwater heaters are often part of the design. Feedwater
heaters are classified as either closed or open designs and are designed for operating at low or high
pressure.
3.1 Closed feedwater heaters
Closed feedwater heaters are specialized shell and tube heat exchangers. The steam flows
from an extraction stage of the turbine and condenses on the shell side of the feedwater heater,
while the feedwater flows inside the tubes and absorbs heat and thereby increases its
temperature.
Most closed feedwater heaters are composed of bundles of a large number of tubes that are
bent in the form of a U, and therefore, this type of design is called a U-tube heat exchanger or
feedwater heater. The tubes are either expanded or welded into tube sheets at one end of the
shell. A series of baffles and tube support plates are used to direct flow, minimize tube
vibration, reduce erosion, and promote high heat transfer. The lowest-cost closed feedwater
heaters are typically long, horizontal, two-pass designs with high water velocities.
Low-pressure feedwater heaters are located prior to (upstream) the boiler feed pump (see
Figure 1). They are generally designed for tube side pressures of less than 900 psig for utility
boiler designs. The location of the feedwater heater relative to the boiler feed pump generally
defines whether it is called a low- or high-pressure heater no matter what the actual pressure is.
High-pressure heaters of a plant cycle are those heaters which are located after (downstream)
the boiler feed pump.
4



The illustration shown in Figure 2 is a U-tube feedwater heater design. The feedwater enters
the lower portion of the heater through the inlet nozzle and proceeds to the feedwater outlet
nozzle through the horizontal U-tubes in basically a two-pass system. Steam from extraction
stages in the steam turbine enters at the top of the heater and flows in a counterdirection, also
in a two-pass flow arrangement, and flows over the tubes where the steam condenses and
leaves the feedwater heater through the drain outlet nozzle. Since the system is closed, these
condensate drains cascade through other feedwater heaters and eventually to the boiler feed
pumps, where all the condensate becomes the feedwater that is recycled continually to the
boiler. Rollers are provided on this design to handle the expansion of the feedwater heater
during operation.


The closed feedwater heater shown in Figure 3 is different from a U-tube design in that
straight tubes are used between two tube sheets. Feedwater heaters of this type are classified
as one-, two-, three-, or four-pass designs depending on the number of times the water passes
the length of the unit before it is discharged. The design shown in Figure 3 is baffled and
provides four passes for the water.
5



As noted previously, the U-tube design of a feedwater heater is the preferred choice of heaters
in todays power plants. This design has minimized the expansion problems of tubes being
connected to two tube sheets. The tubes are bent into the form of the letter U, and these tubes are
frequently referred to as hairpin tubes. Both ends of these tubes are expanded into the same tube
sheet, and the water box is baffled to direct the flow of water through the tubes from one pass to
the other. Although both ends of these tubes are rigidly attached to the tube sheets, their shape
permits free expansion. However, because of their U shape, these tubes cannot be cleaned easily by
mechanical means. But by having good water quality, the need for this cleaning has been reduced
significantly. Also, because of concerns about potential transport of copper from the feedwater
heaters into the boiler and turbine, stainless steel and carbon steel tubes generally are used in
feedwater heaters.
The tube sections of closed feedwater heaters must withstand the pressure of the water, and
the shell must withstand the pressure of the steam. The water is forced through one or more
heaters by a single pump. High-pressure steam plants use heaters between the boiler feed pumps
and the boilers, exposing the water side of the heater to the full boiler feed pump pressure. These
are called high-pressure heaters. The low-pressure heaters are located between the condensate
pumps and the boiler feed pumps. (Refer to Figure 1.) Safety measures in the form of relief valves
must be installed to prevent the possibility that either the water or the steam pressure will exceed
that for which the heater was built.

3.2 Open feedwater heaters (deaerators)
These feedwater heaters are also called deaerators, and they serve the dual purpose of heating
the feedwater to improve plant efficiency and deaerating the feedwater to remove gases that could
cause corrosion of equipment and piping systems. Deaerators also provide the storage of high-
quality feedwater for the boiler feed pump. Several deaerator arrangements are shown in Figures. 4
and 5.
6




7

Heat transfer in deaerators is by direct contact between the feedwater and the turbine
extraction steam, and various design techniques are used such as bubbling, tray, spray, or
various combinations of these. The drains from the high-pressure heaters usually flow into the
deaerator, and noncondensable gases are vented to the atmosphere.
Two types of deaerating heaters are used most often in todays power plants: (1) the spray-
tray type and (2) the spray-scrubber type. Schematics of these designs are shown in Figure 6.

8





The feedwater that must be treated by the deaerator can vary significantly depending on
the plants application. A closed-loop system found in a typical utility has feedwater makeup
requirements of only a few percent, while an industrial application such as a pulp and paper
plant has requirements for feedwater makeup of 40 to 70 percent of the total flow.
Condensate that returns from a turbine is usually high in temperature and low in O
2
and
CO
2
. For industrial plants where makeup water may come from a number of sources, this water
is usually much cooler and can contain high levels of dissolved O
2
and CO
2
. Each situation
requires a careful design and selection of the proper equipment.

3.2.1 Spray-type deaerator
The spray-type deaerator has three main sections, as shown in Figure 6a:
a. A water box at the top, where water enters the unit through valves or nozzles
b. A spray area immediately below, where sprayed water interacts with steam to do 95
percent of the deaerating and heating of the feedwater
c. A tray section, where the final 5 percent of the deaeration and heating takes place

Below the tray tank is a temporary storage area for oxygen-free water. In most large
units, the entire heater is mounted above a storage tank for volume retention. In some
smaller units, the bottom of the heater serves as the storage area. The water box holds
9

incoming water so that it may be evenly sprayed to the chamber below. Because of the
potential for corrosion, the water box is constructed of stainless steel or lined with
stainless steel.
The heater valves are held open by the pressure of water from above. Increasing
feedwater flow forces the valves open further until full capacity is reached. These valves
are also stainless steel. The spray chamber is the large area directly below the water
box, where water meets the upward moving steam for the first time.
The operation of the tray area may seem of minor importance,since only 5 percent
of the deaeration and heating takes place in the trays. The importance of the trays
becomes apparent when it is realized that a deaerator heater must ensure minimum O
2

levels in the feedwater of about 7 parts per billion (ppb). It is in these trays that the
cleanest steam meets the almost completely cleaned water for final polishing. These
trays are also made from stainless steel for corrosion protection.
Below the tray station, at the bottom of the heater tank, there is a section where
deaerated water is briefly retained before it drops into a separate storage tank. In one-
piece heaters, the heater storage volume must be sufficient to permit water to be
drawn off and directed to the boiler feed pumps.
3.2.2 Spray-scrubber deaerator.
In this deaerator design, a scrubber section is used in place of trays, as shown in
Figure 6b. This design accomplishes the same thing as the tray design by removing
residual dissolved gases from water that has passed through the spray chamber. While
the steam can be counterflow, cross flow, or parallel flow to the water in tray-type
deaerators, it is parallel flow in the scrubber section of spray scrubbers, as shown in
Figure 6b.
Turbulent mixing and scrubbing take place as water and steam are in intimate
contact and rise through this region. Assisted by the turbulence caused by steam
condensation, this results in a highly effective gas stripping action.
Spray-scrubber units are generally less expensive than tray types. However, they do
have a disadvantage when compared with tray types in that their turndown range
(design flow/low flow) is about 5:1, whereas a tray type can operate efficiently in a flow
range of 10:1. Selection of the type of deaerator is often based on the load variations
that are expected at the plant.

3.3 Operation and maintenance of feedwater heaters
Damage to feedwater heaters has involved primarily tube failures, which have been caused by
the following:
a. Erosion from steam impingement
b. Tube vibration
c. Erosion and corrosion on the inlet tube end
d. Oxygen pitting
e. Stress corrosion cracking
In addition, failures of tube joints, improper plugging, and poor maintenance all lead to
downtime and repairs of feedwater heaters. Generally, feedwater heaters require no daily
maintenance; however, associated valves need to be given attention. During scheduled outages,
nondestructive examination (NDE) techniques are used for tube-side and shell-side inspections.
Since tube conditions are critical, eddy current and ultrasonic testing (UT) are used to evaluate
tube integrity. Eddy current testing determines wall thinning and identifies cracks that have
occurred.
10

When leaks are detected, tubes are usually plugged with tapered or mechanical plugs and
are expanded in the tubesheet. Explosive plugs are also used. Units can have 10 to 30 percent of
their tubes plugged and still meet thermal performance, although the pressure drop does
increase and the condensate and boiler feed pumps must be designedto handle this additional
pressure requirement.
The feedwater heater system has a significant impact on steam system performance. Much
of the deposits found in steam-generating systems come from corrosion products and
contaminants whose source is the feedwater heater system. Copper-based tubing has been
replaced by other materials in order to reduce the carry-over of dissolved copper. Proper
chemistry control and deaeration operation can minimize corrosion in the feedwater heater
system and reduce corrosion product carry-over into the boiler. The proper control of oxygen is
very important so that corrosion of the boiler system is minimized.
Feedwater heaters may be taken out of service for maintenance during plant operation by
bypassing the feedwater around them and shutting off the extraction steam to them. However,
this requires additional piping and valves, and the system must be designed to accommodate
the bypassing.

4. Compressed Liquid
A compressed liquid is one whose pressure is higher than the saturation pressure corresponding
to its temperature. A subcooled liquid is one whose temperature is below the saturation
temperature corresponding to its pressure. These two definitions define identical states, mean the
same thing, and the names are customarily used interchangeably. In Figure 7, imagine a saturated
liquid in state d, and let it cool at constant pressure to either state B, c or b. It has become
subcooled. On the other hand, imagine a saturated liquid at a, Figure 7; let it be pumped to a higher
pressure bcBd. If it is pumped isothermally, the end state is b; if isentropically, the end state is c; if
isometrically (v = C), the end state is B. Each of these states represents compressed liquid.

11

Typically, vapor tables do not give properties of compressed liquid (an exception, the ASME
S.T.), which means that a good estimate is convenient. The easiest assumption is that the liquid is
incompressible, in which case, points b, c, and B are quite close together. First for a reversible
pumping where AK = 0, AP = 0, we have
dh dW = or
s
h W A =
where the subscript s indicates constant entropy, process ac, Figure 7. Then with Tds = 0, we have
vdp dh = or p v dp v h A = = A
}

Observe that vAp is the rectangular area naBm, Figure 7(a); v = v
a
= v
f
is the saturated liquid volume
available in vapor tables. Let p
a
= p
sat
, meaning the saturation pressure from which the liquid was
imagined to have been pumped to the actual pressure p
act
. Then
( )
sat act f f B c
p p v h h h + = ~ or ( )
sat act f f B
p p v h h =
an approximation of the state after isentropic pumping if the liquid is nearly incompressible.
In dealing with compressed liquid, decide first whether or not any adjustment of saturated-state
properties is needed. If the answer to this question is yes, then decide whether the approximation
involved in the above equation is appropriate. These are engineering decision easily made with a
background of experience. In the meantime, for pedagogical purposes for H
2
O, let us say: when p
400 psia, use saturated liquid properties, at the specified temperature, for compressed liquid
properties; when p > 400 psia, make an accurate or an approximate correction, depending on the
accuracy needed and the facilities at hand.

Example No. 1
Water at 1300 psia is delivered to a steam generator. The exit state from the superheater is defined
by 1100 psia and 1100 F. The condenser pressure is 2.223 psia. The pump receives the liquid at 110
F. (a) For a pump efficiency of 70%, what is the specific pump work? The heat supplied in the steam
generator? (b) Compute the approximate pump work needed to deliver 3.6 x 10
6
lb/hr.
Given:
Steam generator = 1300 psia
Superheater = 1100 psia, 1100 F
Condenser pressure = 2.223 psia.
m = 3.6 x 10
6
lb/hr
q
p
= 70%
Required:
(a) Specific pump work, Heat supplied in the steam generator.
(b) Approximate pump work
Solution:

12

At state 1, 1100 psia, 1100 F
h
1
= 1559.4 Btu/lb
At state 3, 2.223 psia, sat.
h
3
= h
f
= 97.95 Btu/lb
v
3
= 0.0016247 ft
3
/lb
At state 4, 1300 psia
By approximation.
( )
3 4 3 3 4
p p v h h + =
( )( )( )
Btu lb ft
ft in psia lb ft
lb Btu h

+ =
16 778
144 223 2 1300 0016247 0
95 97
2 2 3
4
.
. .
.
lb Btu h 34 98
4
. =
At state 4.
3 4
3 4
h h
h h
p

=
'
q
95 97
95 97 34 98
7 0
4
.
. .
.

=
'
h

lb Btu h 51 98
4
. =
'

(a) Specific pump work = h
4
h
3
= 98.51 97.95 = 0.56 Btu/lb
Heat supplied in the steam generator = h1 h4 = 1559.4 98.51 = 1460.9 Btu/lb
(b) Pump work
( ) ( )( ) hr Btu h h m W
p
000 016 2 56 0 10 6 3
6
3 4
, , . . = = =
'


5. Specific Speed and Impeller Configurations
A dimensionless index of pump type known as specific speed has been developed for pump
design and selection to show the relationship between pump capacity, head, and impeller speed.
Specific speed of an impeller is defined as the speed in revolutions per minute at which a
geometrically similar impeller would operate to deliver 1 gpm at a developed head of 1 ft. Specific
speed is algebraically defined as

4
3
h
Q n
N
s
=


where
N
s
= specific speed;
n = pump speed, rpm;
Q = pump flow at best efficiency point (), gpm; and
h = pump developed head at , ft.

Specific speed characterizes the shape and configuration of an impeller. Since the ratios of the
major impeller dimensions vary uniformly with specific speed, specific speed is useful to the pump
designer in determining impeller proportions and dimensions required, as well as to the application
engineer in checking suction limitations of the pump.
It should be noted that the above equation for specific speed is written for single-stage pump
applications. For multistage pumps, the head per stage is used to calculate specific speed.
Generalizing, the head per stage is found by dividing the total head of the pump by the number of
stages of the pump.
13

Impeller form and proportions vary with specific speed, as shown in Figure 8. Each type of
impeller has been found to have a range of specific speeds in which it will give the best
performance. Radial-vane area impellers have specific speeds up to about 1,000, whereas Francis-
vane area impeller specific speeds go up to 4,000 to 4,500. The specific speeds of mixed flow area
impellers range from that of the Francis-vane impellers up to about 9,500 to 10,000. The specific
speeds of axial flow area impellers range from 10,000 to 14,000. Generally, as flow goes up and
pump head decreases, specific speed increases.


For power station centrifugal pump applications, the following specific speeds and impeller
profiles are generally seen:

In addition, the impeller configuration and specific speed characterize the shape of the pump
operating head-capacity curve, as shown in Figure 9.
14




6. Affinity Laws
Another important tool used by pump designers and application engineers is Affinity Laws.
These laws express the mathematical relationship and illustrate the effect of changes in pump
operating conditions or pump performance variables such as pump head, flow, speed, horsepower,
and pump impeller diameters. The affinity laws are
Flow
|
|
.
|

\
|
|
|
.
|

\
|
=
1
2
1
2
1 2
D
D
n
n
Q Q
Head
2
1
2
2
1
2
1 2
|
|
.
|

\
|
|
|
.
|

\
|
=
D
D
n
n
h h
Horsepower
3
1
2
3
1
2
1 2
|
|
.
|

\
|
|
|
.
|

\
|
=
D
D
n
n
hp hp

where
Q = pump flow, gpm (m
3
/h);
15

n = pump speed, rpm;
D = impeller diameter, in. (m);
h = pump head, ft (m);
hp = pump brake horsepower, bhp (kw); and

Efficiency
1 2 p p
q q = ,
(Nearly constant for pump speed changes and small changes in impeller diameter)

7. Regenerative Feedwater Heating
Increasing the average temperature of heat addition can also be accomplished by increasing the
temperature of the feedwater entering the boiler. To realize a gain in efficiency, heat from within
the cycle is used to elevate the feedwater temperature. This can be done by extracting a portion of
the partially expanded steam from the turbine and directing it to a heat exchanger that heats the
feedwater to the boiler. This process is called regenerative feedwater heating. Figure 10 shows the
equipment arrangement and T-s diagram for the regenerative Rankine cycle. Steam enters the
turbine at state 1 and is partially expanded to state 2. A portion of the steam is extracted at state 2
and sent to a feedwater heater operating at state 6. The remainder of the steam expands through
the steam turbine to state 3. Heat is rejected as the turbine exhaust steam is condensed in process
3-4. The condensate is pumped to the feedwater heater and mixed with the turbine extraction
steam to become saturated liquid at state 6. The feedwater is pumped to the boiler pressure (state
8), heated to saturation, and evaporated in the boiler to reenter the turbine at state 1. The low
temperature heat addition into the cycle (5-6) is avoided and the improvement in efficiency comes
from the increase in the average temperature of heat addition. This is difficult to show graphically
on the T-s diagram. Because the flow rates are not equal at all of the state points on the T-s diagram,
the areas do not represent the total work and heat rejected of the cycle. Rather they represent the
work and heat rejected per pound of steam.
16


Example No. 2
There are received 150,000 lb/hr of steam by an ideal regenerative engine, having only one heater,
of which the heater receives 33,950 lb/hr; the condenser receives the remainder at 1 psia. If the
heater pressure is 140 psia, find the state (quality or Sh) of the steam (a) at the heater entrance, (b)
at the condenser entrance.
Given:
Steam entering engine = 150,000 lb/hr
Steam extracted = 33,950 lb/hr
Condenser pressure = 1 psia
Heater pressure 140 psia
Required:
Quality or SH of the steam (a) at the heater entrance, (b) at the condenser pressure.
Solution:
17


Let m = 150,000 lb/hr
226333 0
000 150
950 33
1
.
,
,
= = m
At state 6, 140 psia
h
6
= h
f
= 324.96 Btu/lb
At state 4, 1 psia
h
4
= h
f
= 69.72 Btu/lb
v
4
= 0.0016136 ft
3
/lb
At state 5,
( )
4 5 4 4 5
p p v h h + =
( )( )( )
Btu lb ft
ft in psia lb ft
lb Btu h

+ =
16 778
144 1 140 0016136 0
72 69
2 2 3
5
.
.
.
lb Btu h 76 69
5
. =


18

Heat balance in the heater:


( )
6 2 1 5 1
1 h h m h m = +
( )( ) 96 324 226333 0 76 69 226333 0 1
2
. . . . = + h
lb Btu h 3 1197
2
. =
(a) At the heater entrance, 140 psia, t
sat
= 353.04 C
h
f
= 324.96 Btu/lb
h
g
= 1192.96 Btu/lb
h
fg
= 868 Btu/lb
Since h
2
> h
g
, there is a superheat.
Temperature = 360.13 C
Superheat = 360.13 353.04 = 7.09 C
Then s
2
= 1.58047 Btu/lb-R
(b) At the condenser entrance, 1 psia, s
3
= s
2
= 1.58047 Btu/lb R
s
f
=0.13262 Btu/lb-R
s
fg
= 1.84553 Btu/lb-R
For quality x,
% . .
.
. .
45 78 7845 0
84553 1
13262 0 58047 1
3
= =

=
fg
f
s
s s
x


8. Heat Balance Calculations for Surface Heaters
Terminal difference for a surface heater is defined in the same way as the difference between
the saturation temperature of the steam in the heater and the temperature of the water leaving the
heater. Saturation temperature is always used, even though the steam may be entering the heater
in a superheated state.
Steam requirements for a heater may be determined by the Law of Conservation of Energy; or,
all the energy entering a system during a given period of time must be equal the energy leaving
during the same period when the process is steady flow.
19


Making the energy balance around the heater, Figure 6, we get:
Leaving
d
Entering
s
h W h S h W h S
2 1
+ = +
With one equation we may have one unknown. Usually, but not always, the unknown is the
steam required, S. Solving for S,
( )
d s
h h
h h W
S

=
1 2

where
S = steam flow, lb per hr
W = water flow, lb per hr
h
s
= enthalpy of the steam, Btu per lb
h
d
= enthalpy of drains corresponding to saturated liquid at steam pressure, Btu per lb
h
1
= enthalpy of water entering corresponding to temperature t
1
, Btu per lb
h
2
= enthalpy of water leaving, corresponding to temperature t
2
= t
sat
TD , Btu per lb
p = steam pressure, psia
t
sat
= saturation temperature of steam, F
t
1
= temperature of water entering, F
t
2
= temperature of water leaving, F
TD = terminal difference, F



Example No. 3
Find the amount of steam needed by the heater, Figure 11, at 75 psia, 350 F, with 5 F TD, 350,000 lb
per hr of water entering at 260 F.
Given:
Steam at 75 psia, 350 F
TD = 5 F
W = 350,000 lb per hr
t
1
= 260 F
Required: S
20

( )
d s
h h
h h W
S

=
1 2

h
s
= h at 75 psia and 350 F = 1205.3 Btu per lb
t
sat
= 307.6 F
t
2
= t
sat
TD = 307.6 5 = 302.6 F
h
d
= h
f
at 75 psia = 277.4 Btu per lb
h
1
= h
f
at 260 F = 228.6 Btu per lb
h
2
= h
f
at 302.6 F = 272.3 Btu per lb
( )
hr lb S 480 16
4 277 3 1205
6 228 3 272 000 350
,
. .
. . ,
=

=

9. Heat Balance Calculations for Deaerators and Contact Heaters.
Heat-balance calculations for a deaerator are no different from those for a contact heater. The
calculations assume that the heater is perfectly insulated, that the process is one of steady flow, and
that the process is one of steady flow, and that the loss of energy from the vent to atmosphere or
some other region is negligible. If a vent condenser is used with the equipment, it is considered a
part of the heater for heat-balance calculations.
The same two laws that define the performance of all heat-exchange equipment are used for
contact-heater calculations. The Law of Conservation of Energy applies to the energy exchange and
the Law of Conservation of Mass applies to the weights flowing. Refer to Figure 11.


Energy entering = energy leaving
2 2 1 1
h W h W h S
s
= +
where
S = steam flow, lb per hr
W
1
= water entering, lb per hr
W
2
= water leaving, lb per hr
h
s
= steam enthalpy, Btu per lb
h
1
= enthalpy of entering water, Btu per lb
21

h
2
= enthalpy of water leaving, Btu per lb

Regardless of the number of fluids entering the heater, the energy balance must always hold
true. The enthalpy of the water leaving should be taken at zero terminal difference. A typical
application of this equation would contain two unknowns, S and W1. But, applying the second of the
two laws, we get
2 1
W W S = +

Solving for steam quantity,

( )
1
1 2 2
h h
h h W
S
s

=

Example No. 4
Steam enters a contact type of heaters at 145 psia and 1264.0 Btu per lb. The heater discharges
550,000 lb per hr of water; the entering temperature is 286 F. Find the steam required.
Given:
Steam pressure = 145 psia
h
s
= 1264.0 Btu per lb
W
2
= 550,000 lb per hr
t
s
at 145 psia = 355.8 F
h
1
= h
f
at 286.0 F = 255.2 Btu per lb
h
2
= h
f
at 355.8 F = 327.7 Btu per lb

Required: Steam flow, S
Solution:
( )
1
1 2 2
h h
h h W
S
s

=

( )
hr per lb S 530 39
2 255 0 1264
2 255 7 327 000 550
,
. .
. . ,
=

=

hr per lb S W W 470 510 530 39 000 550
2 1
, , , = = =

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